Nestably stackable formed wire foundation

Abstract

A nestably stackable pre-assembly for a box spring foundation having a top support surface formed by a substantially rectangular border wire, lateral surface support wires and longitudinal surface support wires. The top support surface is supported by a series of longitudinal formed wire structural support members having V-shaped sections extending down from the top support surface. The structural support members are attached to the surface support wires by clips. The V-sections of adjacent structural support members are angled towards each other in pairs such that they form a series of four-sided open-apex pyramids. The pre-assemblies can be stored and shipped by attaching a first pre-assembly to a bottom wooden frame, and stacking additional pre-assemblies on top of the first.

What is claimed is: 
     
       1. A nestably stackable box spring pre-assembly comprising: (a) a substantially rectangular border wire having two ends and two sides defining a top support surface;   (b) a plurality of lateral surface support wires extending across the top support surface attached at each end to one side of the substantially rectangular border wire;   (c) a plurality of longitudinal surface support wires extending along the length of the top support surface attached at each end to one end of the substantially rectangular border wire, and intersecting the lateral surface support wires to form intersection points, wherein each of the longitudinal surface support wires is attached to at least one of the plurality of lateral surface support wires at an intersection point;   (d) a plurality of pairs of adjacent structural support wires, each structural support wire having (i) two end sections,   (ii) at least one V section,   (iii) a plurality of lateral sections and   (iv) a plurality of offset longitudinal sections, said structural support wires extending substantially from one end of the substantially rectangular border wire to the other end of the substantially rectangular border wire; and       (e) a plurality of means for rigidly attaching the lateral sections of the structural support wire to the lateral surface support wires,   wherein the V sections of each structural support wire are contained within a common plane, the V section containing common planes of adjacent structural support wires extending downwardly and inwardly toward one another from said rod support surface such that the vertices of the V sections of a pair of adjacent support wires are close to but not in contact with the vertices of the adjacent structural support wire of said pair and such that adjacent V sections in one pair of structural support wires form an open apex pyramidal structure.   
     
     
       2. The nestably stackable box spring pre-assembly of claim 1, wherein the means for rigidly attaching the lateral sections of the structural support wires to the lateral surface support wires are clips. 
     
     
       3. The nestably stackable box spring pre-assembly of claim 1, wherein each structural support wire is attached to one of the longitudinal surface support wires at each end of the structural support wire. 
     
     
       4. The nestably stackable box spring pre-assembly of claim 1, wherein the length of each offset longitudinal section is substantially equal to the distance between two adjacent lateral surface support wires. 
     
     
       5. The nestably stackable box spring pre-assembly of claim 1, wherein the structural support wires further comprise notch sections, said notch sections being formed such that each notch section curves up along the side of a longitudinal surface support wire and rises slightly above the longitudinal and lateral support wires. 
     
     
       6. The nestably stackable box spring pre-assembly of claim 5, wherein the notches in a pair of adjacent structural support wires curve up on alternate sides of adjacent longitudinal surface support wires. 
     
     
       7. The nestably stackable box spring pre-assembly of claim 1, wherein the end sections extend downwardly at an angle of substantially 90° from the top support surface. 
     
     
       8. The nestably stackable box spring pre-assembly of claim 1, wherein each end section comprises a substantially closed loop end portion. 
     
     
       9. The nestably stackable box spring pre-assembly of claim 1, wherein the common plane containing the V sections of each structural support wire extends down from the top surface at an angle that ranges from about 45° to about 75°. 
     
     
       10. The nestably stackable box spring pre-assembly of claim 1, further comprising an additional plurality of longitudinal surface support wires, said additional longitudinal surface support wires being positioned directly above the open apexes of the pairs of adjacent structural support wires. 
     
     
       11. The nestably stackable box spring pre-assembly of claim 1, wherein each V section has a short flat section at the vertex of the V section. 
     
     
       12. The nestably stackable box spring pre-assembly of claim 1, wherein each structural support wire comprises three V sections. 
     
     
       13. The nestably stackable box spring pre-assembly of claim 1, wherein each structural support wire comprises four V sections. 
     
     
       14. A structural support wire for a box spring foundation comprising: (a) two end sections wherein each end section comprises a substantially closed loop portion;   (b) a plurality of V sections located between said end sections, each V section having a short flat segment at its vertex and lying in a common plane;   (c) a plurality of relatively short lateral sections; and   (d) a plurality of relatively long offset longitudinal sections.   
     
     
       15. The structural support wire of claim 14, wherein the structural support wire has three V sections. 
     
     
       16. The structural support wire of claim 14, wherein the structural support wire has four V sections. 
     
     
       17. A stack of box spring pre-assemblies comprising: (a) one bottom pre-assembly comprising: (i) a substantially rectangular border wire having two ends and two sides defining a support surface for the bottom pre-assembly;   (ii) a plurality of lateral surface support wires, extending across the support surface of the bottom pre-assembly, attached at each end to one side of the substantially rectangular border wire;   (iii) a plurality of longitudinal surface support wires extending along the length of the support surface of the bottom pre-assembly, attached at each end to one end of the substantially rectangular border wire, and intersecting the lateral surface support wires to form intersection points, wherein each of the longitudinal surface support wires is attached to at least one of the plurality of lateral surface support wires at an intersection point;   (iv) a plurality of pairs of adjacent structural support wires, each structural support wire having two end sections, at least one V section, a plurality of lateral sections and a plurality of offset longitudinal sections, said structural support wires extending substantially from one end of the substantially rectangular border wire to the other end of the substantially rectangular border wire;   (v) a plurality of means for rigidly attaching the lateral sections of the structural support wire to the lateral surface support wires,   (vi) a frame having two ends and two sides positioned directly below the two ends and two sides of the substantially rectangular border wire, and having a plurality of slats, wherein the bottom of the end sections of the structural support wires are rigidly attached to the ends of the frame, and the bottom of each at least one V section of the structural support wires is rigidly attached to the slats;     wherein the V sections of each structural support wire are contained within a common plane, the V section containing common planes of adjacent structural support wires extending downwardly and inwardly toward one another from said top support surface such that the vertices of the V sections of a pair of adjacent support wires are close to but not in contact with the vertices of the adjacent structural support wire of said pair and such that adjacent V sections in one pair of bottom structural support wires form an open-apex pyramidal structure; and   (b) at least one additional pre-assembly comprising: (i) an additional substantially rectangular border wire having two ends and two sides defining an additional top support surface;   (ii) a plurality of additional lateral surface support wires extending across the additional top support surface attached at each end to one side of the additional substantially rectangular border wire;   (iii) a plurality of additional longitudinal surface support wires extending along the length of the additional top support surface attached at each end to one end of the additional substantially rectangular border wire, and intersecting the additional lateral surface support wires to form intersection points, wherein each of the additional longitudinal surface support wires is attached to at least one of the plurality of additional lateral surface support wires at an intersection point;   (iv) a plurality of pairs of adjacent additional structural support wires, each additional structural support wire having two end sections, a plurality of V sections, a plurality of lateral sections and a plurality of offset longitudinal sections, said additional structural support wires extending substantially from one end of the additional substantially rectangular border wire to the other end of the additional substantially rectangular border wire; and   (v) a plurality of means for rigidly attaching the additional lateral sections of the additional structural support wire to the additional lateral surface support wires,     wherein the V sections of each additional structural support wire are contained within a common plane, the V section containing common planes of adjacent additional structural support wires extending downwardly and inwardly toward one another from said additional top support surface such that the vertices of the V sections a pair of adjacent additional support wires are close to but not in contact with the vertices of the adjacent additional support wire of the pair, and such that adjacent V sections in one pair of additional structural support wires form a open-apex pyramidal structure,   and wherein each additional pre-assembly is stacked sequentially on top of the bottom pre-assembly.   
     
     
       18. A box spring assembly comprising: (a) a substantially rectangular border wire having two ends and two sides defining a top support surface;   (b) a plurality of lateral surface support wires extending across the top support surface attached at each end to one side of the substantially rectangular border wire;   (c) a plurality of longitudinal surface support wires extending along the length of the top support surface of the box spring assembly attached at each end to one end of the substantially rectangular border wire, and intersecting the lateral surface support wires to form intersection points, wherein each of the longitudinal surface support wires is attached to at least one of the plurality of lateral surface support wires at an intersection point;   (d) a plurality of pairs of adjacent structural support wires, each structural support wire having two end sections, at least one V section, a plurality of lateral sections and a plurality of offset longitudinal sections, said structural support wires extending substantially from one end of the substantially rectangular border wire to the other end of the substantially rectangular border wire;   (e) a plurality of means for rigidly attaching the lateral sections of the structural support wire to the lateral surface support wires;   (f) a frame having two ends and two sides positioned directly below the two ends and two sides of the substantially rectangular border wire, and also having a plurality of slats, wherein the bottom of the end sections of the structural support wires are attached to the ends of the frame, and the bottom of each V section of the structural support wires is attached to a slat, and   wherein the V sections of each structural support wire are contained within a common plane, the V section containing common planes of adjacent structural support wires extending downwardly and inwardly toward one another from said top support surface such that the vertices of the V sections of a pair of adjacent support wires are close to but not in contact with the vertices of the adjacent structural support wire of said pair and such that adjacent V sections in one pair of structural support wires form a open-apex pyramidal structure.   
     
     
       19. The box spring assembly of claim 18, wherein the means for rigidly attaching the lateral sections of the structural support wires to the lateral surface support wires are clips. 
     
     
       20. The box spring assembly of claim 18, wherein each structural support wire is attached to one of the longitudinal surface support wires at each end of the structural support wire. 
     
     
       21. The box spring assembly of claim 18, wherein the length of each offset longitudinal section is substantially equal to the distance between two adjacent lateral surface support wires. 
     
     
       22. The box spring assembly of claim 18, wherein the structural support wires further comprise notch sections, said notch sections being formed such that each notch section curves up along the side of a longitudinal surface support wire and rises slightly above the longitudinal and lateral support wires. 
     
     
       23. The box spring assembly of claim 18, wherein the notches in a pair of adjacent structural support wires curve up on alternate sides of adjacent longitudinal surface support wires. 
     
     
       24. The box spring assembly of claim 18, wherein the end sections extend downwardly at an angle of substantially 90° from the top support surface. 
     
     
       25. The box spring assembly of claim 18, wherein each end section comprises a substantially closed loop end portion. 
     
     
       26. The box spring assembly of claim 18, wherein the common plane containing the V sections of each structural support wire extends down from the top support surface at an angle ranging from about 45° to about 75°. 
     
     
       27. The box spring assembly of claim 18, further comprising an additional plurality of longitudinal surface support wires, said additional longitudinal surface support wires being positioned directly above the open apexes of the pyramidal structures. 
     
     
       28. The box spring assembly of claim 18, wherein each V section has a short flat section at the vertex of the V section. 
     
     
       29. A nestably stackable box spring pre-assembly comprising: (a) a substantially rectangular border wire having two ends and two sides defining a planar top support surface;   (b) a plurality of surface support wires including: (i) lateral surface support wires extending across the top support surface attached at each end to one side of the substantially rectangular border wire, and   (ii) a plurality of longitudinal surface support wires extending along the length of the top support surface attached at each end to one end of the substantially rectangular border wire, and intersecting the lateral surface support wires to form intersections points, wherein each of the longitudinal surface support wires is attached to substantially all of the plurality of lateral surface support wires at an intersection point;     (c) a plurality of pairs of adjacent structural support wires, each structural support wire having two end sections, a plurality of notch sections and a plurality of V sections, said structural support wires extending substantially from one end of the substantially rectangular border wire to the other end of the substantially rectangular border wire, said notch sections rising above said longitudinal surface support wires; and   (d) a plurality of means for rigidly attaching the structural support wires to the surface support wires,   wherein the V sections of each structural support wire are contained within a common plane, the V section containing common planes of adjacent structural support wires extending downwardly and inwardly toward one another from said top support surface such that the vertices of the V sections of a pair of adjacent support wires are close to but not in contact with the vertices of the adjacent structural support wire of said pair and such that adjacent V sections in one pair of structural support wires form an open apex pyramidal structure.   
     
     
       30. The nestably stackable box spring pre-assembly of claim 29, wherein the means for rigidly attaching the structural support wires to the surface support wires are clips. 
     
     
       31. The nestably stackable box spring pre-assembly of claim 29 wherein said notches are in physical contact with the lateral support wires. 
     
     
       32. The nestably stackable box spring pre-assembly of claim 29, wherein the end sections comprise a substantially closed end portion. 
     
     
       33. The nestably stackable box spring pre-assembly of claim 29, further comprising an additional plurality of longitudinal surface support wires, said additional longitudinal surface support wires being positioned directly above the apex of the four-sided pyramidal structure formed by adjacent V sections. 
     
     
       34. The nestably stackable box spring pre-assembly of claim 29, wherein each V section has a short flat section at the vertex of the V section. 
     
     
       35. The nestably stackable box spring pre-assembly of claim 29, further comprising a frame having two ends and two sides, having a plurality of slats extending laterally from one side of the frame to the other side of the frame, wherein the bottom of the end sections of the structural support wire are rigidly attached to the ends of the frame, and the bottom of the V sections of the structural support wire are attached to the slats.